Method and apparatus for interleaved switching of track segments in a motion control system

An apparatus for controlling activation of a plurality of coils in a linear drive system, the apparatus comprising:

• a DC bus having a first voltage rail and a second voltage rail, wherein each of the first voltage rail and the second voltage rail conduct a different voltage potential;
• a plurality of output connections, wherein each output connection is connected to one of the plurality of coils;
• a plurality of switching devices operatively connected between one of the first voltage rail and the second voltage rail and one of the plurality of output connections to selectively connect one of the first voltage rail and the second voltage rail to the corresponding output connection;
• and
• a controller operative to receive a command signal for at least one mover propelled by the linear drive system and to generate a plurality of switching signals, wherein:
• each switching signal controls operation of one of the plurality of switching devices,
• the switching signals are generated responsive to the command signal to sequentially control operation of the corresponding switching device and to propel the at least one mover according to the command signal,
• each of the switching devices are positioned adjacent to each other,
• each of the plurality of coils are positioned adjacent to each other along the linear drive system, and
• at least one of the plurality of coils is located between a first coil and a second coil connected to adjacent switching devices.

A method for controlling activation of a plurality of coils in a linear drive system, comprising the steps of:

• receiving a command signal corresponding to a desired motion for at least one mover propelled by the linear drive system;
• and
• generating a plurality of switching signals as a function of the command signal, wherein:
• each switching signal controls operation of a switching device,
• each of the switching devices are positioned adjacent to each other,
• each of the plurality of coils are positioned adjacent to each other,
• each switching device is operatively connected between one of a first voltage rail and a second voltage rail and one of the plurality of coils,
• each of the switching devices is connected to one of the plurality of coils such that at least one coil is present between each of the coils to which adjacent switching devices are connected, and
• the plurality of switching signals energize switching devices such that coils positioned adjacent to each other are sequentially energized to propel the at least one mover along the linear drive system.